Carton construction

ABSTRACT

A carton is provided wherein the cover thereof is connected to the tray by an elongated hinge panel. One elongated edge of the panel is connected to the tray and forms a first hinge-line and the opposite elongated edge of the panel is connected to the cover and forms a second hinge-line. The first hinge-line has greater flexibility than the second hinge-line. Complemental means are formed on said tray and hinge panel whereby, upon closing of the carton, the cover and hinge panel initially move as a unit about the first hinge-line as an axis through a predetermined arc and then the cover moves relative to the hinge panel about the second hinge-line as an axis through a further predetermined arc into an overlying closed position with respect to the tray.

United States Patent 1191- 14 1 Feb. 5, 1974 CARTON CONSTRUCTION [75] Inventor: James W. Boyd, Crown Point, Ind.

[73] Assignee: Packaging Corporation of Americ Evanston, Ill.

[22] Filed: Sept. 27, 1971 [21] Appl. No.: 183,938

52 us. 01. 229/2.s, 16/DIG. 13, 220/31 s, 229/44 R [51 1111.01 B65d 85/32 [58] Field of Search... 229/2.5, 29 M, 44 R, DIG. 4; 220/31 S; 16/128 R, 150, DIG.'13

[56] References Cited UNITED STATES PATENTS 3,593,910 7/1971 Bessett et a1 229/2.5 3,145,895 8/1964 Reifers 229/2.5 3,501,083 3/1970 Lake 229/2.5 2,771,233 11/1956 Cox. 229/2.5 3,459,359 I 8/1969 Heffernan- 229/44 R 3,655,] 10 4/1972 Eisenbach 229/44 R FOREIGN PATENTS OR APPLICATIONS 750,781 l/1967 Canada 220/31 S Primary Examiner-William T. Dixson, Jr. Assistant Examiner-Stephen Marcus [5 7] ABSTRACT A carton is provided wherein the cover thereof is connected to the tray by an elongated hinge panel. One elongated edge of the panel is connected to the tray and forms'a first hinge-line and the opposite elongated edge of the panel is connected to the cover and forms a second hinge-line. The. first hinge-line has greater flexibility than the second hinge-line. Complemental means are formed on said tray and hingev panel whereby, upon closing of the carton, the cover and hinge panel initially move as a unit about the first hinge-line as an axis through a predetermined arc and then the cover moves relative to the hinge panel about the second hinge-line as an axis through a further predetermined are into an overlying closed position with respect to the tray.

7 Claims, 9 Drawing Figures PAIENIEDFEB Sign 3390.062

SHEEI 2 F 2 CARTON CONSTRUCTION I BACKGROUND OF THE INVENTION In the commercial, automatic high-speed packaging of certain products such as eggs in egg cartons, it is important in reducing the incidents of breakage that the cover of the carton be capable of being moved into and out of closed position with respect to the tray with minimal disturbance to the accomodated eggs. Furthermore, once the cover has been moved to its closed position, it should securely remain in said closed position until it is desired to remove one or more eggs from the carton. Because eggs vary widely in size and shape, it is impractical for the packer to inventory a wide variety of cartons to compensate for the size and shape differentials of the eggs, and thus, a carton capable of effectively accomodating a wide variety of eggs is most desirable. It is customary to place loaded cartons in stacked relation when being shipped to the customeror held in cold storage for future delivery. By reason of this fact, it is important that the loaded carton be possessed of high top-to-bottom strength and thus, protect the accommodated eggs against being crushed Various cartons for eggs have heretofore been produced, however, because of certain design characteristics they have been incapable of successfully meeting all of the aforenoted requisites. One structural feature which has been an important factor in contributing to the lack of success of certain prior cartons has been in the hinge interconnecting the cover and tray.

SUMMARY OF THE INVENTION Thus, it is an object of this invention to provide a carton which is inexpensive to make, provides adequate protection for eggs varying in size and shape over a wide range, and readily permits closing of the loaded cartons by high speed automatic equipment without adversely affecting the eggs.

description, accompanying drawings and appended claims.

In accordance with one embodiment of this, inven tion, a carton is provided which includes a tray, a cover therefor, and a hinge means for interconnecting said cover and tray whereby said cover is movable between a fully opened position wherein th interior of the tray is exposed and a fully closed position wherein said cover overlies the tray in substantially superposed relation. The hinge means includes an elongated hinge panel having one elongated edge thereof connected to the upper edge of the backside of the tray and forming a first hinge-line, and the opposite edge of the hinge panel connected to the lower edge of the backside of the cover and forming a second hinge-line. ,The first hinge-line has greater flexibility than the second hingeline, and thus, when closing the carton, the cover and hinge panel initially move as a unit about the first hinge-line as an axis, and once the hinge panel has reached a substantially upright position, then the cover continues to be folded relative to the hinge panel about the second hinge-line as an axis, to a fully closed position with respect to the tray. Complemental means are provided on the hinge panel and tray for retaining said hinge panel in said upright position during the aforesaid closing operation.

For a more complete understanding of the invention, reference should be made to the drawings wherein:

FIG. I is a top plan view of one form of an egg carton embodying the improved hinge construction and show ing the carton in a-fully open position.

FIG. 2 is a fragmentary bottom plan view of the'carton of FIG. 1 and showing the improved hinge construction thereof.

FIG. 3 is a sectional view taken along line 3-3 of FIG. 1.

FIG. 4 is similar to FIG. 3, but showing the cover thereof in a fully closed'position.

FIG. 5 is a fragmentary sectional view taken along line 55 of FIG. 1.

v FIGS. 6 and 7 are similar to 'FIG. 5, but showing, re-

spectively, the cover and hinge panel being folded as a it may be incorporated in cartons utilized to accommodate other fragile articles besides eggs.

The improved hinge construction 11 is adapted to interconnect the cellular tray 12 and the cover 13 of the carton. The tray 12, in the illustrated embodiment, includes two, parallel, coextensive rows A and B of eggaccommodating cells 14. Each row comprises six longitudinally spaced cells. The upper side of the tray 12 is delimited by a peripheral laterally extending flange 15. The portion of the flange defining the back of the tray is provided with a plurality of lands 16, each of which is aligned with the space between adjacent cells of the row A of cells. Furthermore, each land 16 includes a raised projection 17, see FIGS. 3-7, which has a substantially flat top 17a, and a tapered side 17b which faces outwardly. Corresponding lands 18 are formed along the front portion of the flange 15, except lands 18 do not include projections.

The rows A and B are separated from one another by the tray; and have at least one of the posts, preferably the center one, coacting with a depending post 21 formed in the top panel 22 of the cover 13 to improve the top-to-bottom strength of the carton. The configuration, size, and number of posts 20 and 21 may vary from that shown.

Foldably connected to the front portion of flange may be a bracing flap 23, as shown, or a locking flap, not shown, each of which coacts with the interior surface of the depending front wall 24 of the cover 13 when the latter is in its fully closed position, as seen in FIG. 4. v

The improved hinge 11 interconnecting the tray and cover, includes an elongated, narrow hinge panel 25 which is substantially coextensive with the back portion of flange 15. One (the lower) elongated edge of panel 25 is foldably connected to the back portion of flange l5 and cooperates therewith to form a first hinge-line 26, see FIG. 1. The opposite (or upper) elongated edge of panel 25 is foldably connected to the outer edge of a depending back wall 27 of the cover 13 and cooperates therewith to form a second hinge-line 28. I-lingelines 26 and 28 are in spaced, substantially parallel relation, as seen in FIG. 1.

Hinge panel 25 is provided with a plurality of longitudinally spaced protuberances 30. Each protuberance is aligned with a projection 17 formed in the tray flange 15. Each protuberance 30 is preferably of like configuration and has a distal endface 30a and tapered sides 30b. The extent to which each protuberance projects from the hinge panel 25 is such that the endface 30a will engage the tapered side 17b of the projection 17 upon the panel 25 having been folded through an arc of approximately 90- to an upright position, such as shown in FIG. 6. Once the panel 25 has attained its upright position, the protuberance 30 and projection 17 coact to prevent further folding of the panel in a counter-clockwise direction. Until the panel 25 reaches its upright position, the panel 25 and cover 13 move as a unit in a counter-clockwise direction about the first hinge-line as an axis. Subsequent to panel 25 reaching its upright position, the cover 13 may continue to be folded in a counter-clockwise direction about the second hinge-line 28 as an axis until it reaches a fully closed position, such as shown in FIG. 4.

FIGS. 8-9 show a modified hinge construction 111 wherein the projections 117 there'of formed on the lands of the tray flange 115, each have the outwardly disposed side 1l7b thereof depending at an abrupt, almost right, angle from the top 117a of the projection, whereby the endface 130a of the hinge panel protuberance 130 will abut the side l17b upon the panel 125 reaching its upright position, and thus, prevent the panel from being overfolded. Thus, in the modified construction 1 1 1, the extent to 'which the protuberance 130 projects from the panel 125 is accurately sized with respect to the distance the side 117b of the projection 117 is offset inwardly from the hinge-line 126. Because of this fact, after-pressing in the hinge area might be desirable particularly where the carton is formed of molded pul'p.

In both forms of the illustrated hinge constructions 1 1 and 11 l, the first hinge-line 26 or 126 is more flexible than the second hinge-line 28 or 128. One facile way of accomplishing this result is to cut score seg- It will be noted in FIG. 2, that there are a greater number of cut score segments C in hinge-line 26 than in hinge-line 28 thereby producing the desired flexibility differential. It is preferred that each cut score segment be substantially coextensive with the length of the protuberance 30 formed in the hinge panel 25.

When the cover is being folded about the second hinge-line 28 or 128 as an axis, it is sometimes necessary for the cover to be overfolded a slight amount, as shown in dotted lines in FIG. 7, so as to facilitate interlocking between the cover front wall and a locking flap wherein the latter carries a protruding lug which extends outwardly through an opening formed in the cover front wall, when said opening and lug are in registered relation. Once interlocking has occurred, the projections 17 or 117 coact-with the protuberances 30 or 130 to return the cover to its normally closed position, as seen in full lines in FIGS. 7 and 9, respectively. Where the carton has only a bracing flap 23, as illustrated, no overfolding is required during closing of the cover and the coaction of the projections and protuberances will cause the interior surface of the front wall of the cover to positively engage the outer surface of the flap and maintain the latter in proper bracing position.

In forming either hinge construction 11 or 111, the hinge-lines 26-28 or 126-128 are normally produced by elongated scoring blades, not shown, which are properly positioned on the molds forming the desired carton. Because of the shape and thickness of such score blades, the portions of the hinge panel and cover wall defining hinge-line 28, for example, are compressed slightlyso as to define. an included angle X, see FIG. 6, which is greater than By reason of the included angle being greater than 90, the adjacent portions of the hinge panel and cover wall will not engage one another when the cover'is folded relative to the hinge panel, even though the cover be overfolded, as seenin FIG. 7.

The hinge panel 25 or permits the tray to have deeper cells thereby rendering said tray capable of handling eggs varying in size over a wider range. Furthermore, the hinge panel permits the tray and'cover to rest on a common plane when the carton, during production thereof, is moving through a drying oven. The upright disposition of the hinge panel, when the cover is in its fully closed position, combines with the abutting cover post 21 and center post 20 of the tray to provide great top-to-bottom strength for the carton.

I claim:

1. A carton comprising a cover having a downwardly extending back wall, a tray having an upwardly extending back wall, and an elongated inflexible hinge panel having one elongated edge thereof connected to the upper edge of said tray back wall and forming a first hinge-line and the opposite elongated edge thereof connected to the lower edge of said cover back wall and forming a second hinge-line, said first hinge-line having greater flexibility than said second hinge-line, and protruding complemental abutting means formed on said hinge panel intermediate said first and second hinge-lines and on said tray upper edge and adjacent to said first hinge-line, said abutting means engaging one another only upon said cover and hinge panel having been moved in one direction about said first hinge-line as an axis until said hinge panel is restrained in a substantially upright position against further movement of said hinge panel in said one direction while said cover continues being moved unrestrictively in said one direction about said second hinge-line as an axis until said cover substantially closes said tray.

2. The carton of claim 1 wherein the complemental abutting means formed on said hinge panel includes a plurality of longitudinally spaced first protuberances extending into the interior-of said carton when said hinge panel is in said upright position, said protuberances being separated from one another by relatively inflexible hinge panel portions, and the complemental abutting means formed on said tray upper edge including a corresponding number of second protuberances; said first and second protuberances engaging one another only when said hinge panel is in said upright position.

3. The carton of claim 2 wherein the portions of said hinge panel separating said-first protuberances are of substantially planar configuration.

4. The carton of claim 2-wherein the portion of each second protuberance engaged by the corresponding first protuberance comprises a protruding tapered side wall disposed adjacent said'first hinge-line.

5. The carton of claim 2 wherein each second protuberance is provided with a protruding substantially transversely extending side wall disposed adjacent to said hinge-line and contacted by a distal end of the corresponding first protuberance upon said hinge panel having been moved to said upright position.

6. The carton of claim 1 wherein said first hinge-line is provided with at least one elongated cut score.

7. The carton of claim 6 wherein said first and second hinge-lines are provided with a plurality of aligned longitudinally spaced elongated cut scores, the number of cut scores formed in said first hinge-line being greater than the number formed in said second hinge-line.

Patent No. 3,790,062 Dated February 5, 1974 :Iames W. Boyd a Inventor(s) It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line 10 "a-ccomodated" should be accommodated line 18, "accomodating" should be accommod ating Column 6, line 8 (claim 5) before "hinge-line" insert first Signed and sealed this 25th day of June 1974 (SEAL) Attest:

EDWARD M.FLETCI-IER,JR; c. MARSHALL DANN Attesting Officer Commissioner of Patents F ORM P04 050 (10-69) USCOMM-DC 60376-P09 

1. A carton comprising a cover having a downwardly extending back wall, a tray having an upwardly extending back wall, and an elongated inflexible hinge panel having one elongated edge thereof connected to the upper edge of said tray back wall and forming a first hinge-line and the opposite elongated edge thereof connected to the lower edge of said cover back wall and forming a second hinge-line, said first hinge-line having greater flexibility than said second hinge-line, and protruding complemental abutting means formed on said hinge panel intermediate said first and second hinge-lines and on said tray upper edge and adjacent to said first hinge-line, said abutting means engaging one another only upon said cover and hinge panel having been moved in one direction about said first hinge-line as an axis until said hinge panel is restrained in a substantially upright position against further movement of said hinge panel in said one direction while said cover continues being moved unrestrictively in said one direction about said second hingeline as an axis until said cover substantially closes said tray.
 2. The carton of claim 1 wherein the complemental abutting means formed on said hinge panel includes a plurality of longitudinally spaced first protuberances extending into the interior of said carton when said hinge panel is in said upright position, said protuberances being separated from one another by relatively inflexible hinge panel portions, and the complemental abutting means formed on said tray upper edge including a corresponding number of second protuberances; said first and second protuberances engaging one another only when said hinge panel is in said upright position.
 3. The carton of claim 2 wherein the portions of said hinge panel separating said first protuberances are of substantially planar configuration.
 4. The carton of claim 2 wHerein the portion of each second protuberance engaged by the corresponding first protuberance comprises a protruding tapered side wall disposed adjacent said first hinge-line.
 5. The carton of claim 2 wherein each second protuberance is provided with a protruding substantially transversely extending side wall disposed adjacent to said hinge-line and contacted by a distal end of the corresponding first protuberance upon said hinge panel having been moved to said upright position.
 6. The carton of claim 1 wherein said first hinge-line is provided with at least one elongated cut score.
 7. The carton of claim 6 wherein said first and second hinge-lines are provided with a plurality of aligned longitudinally spaced elongated cut scores, the number of cut scores formed in said first hinge-line being greater than the number formed in said second hinge-line. 